Wave Form Controlled Technology

GMAW Pulse Power Mode Rapid Arc

STT

Agenda

1. 2. a) b) c) d) e) f) 3. 4. 5. 6. 7. 8. 9. 10. 11.

Introduction STT process Background current Initial shorting Pinch current Secont current reduction Peak current Tailout STT visualization STT settings and guidelines Application - austenitic stainless. Cr-Mo low alloyed STT vs. TIG, austenitic stainless, welding time Comparing STT to CV, quality Welding fumes Possible applications Summary benefits FCW for austenitic & duplex stainless

Introduction

Conventional CV
Arc voltage/Welding current
50 35 30 25 20 15 10 5 0
SG2 SG21.0mm 1.0mm 80/20 80/20MIX-gas MIX-gas

100

150

200

250

300

350

Fill ROOT

Spray arc Short arc Globular Transfer

Popular Popularbut..limitations but..limitationsand andclear cleardisadvantages disadvantages

Alternatives

Wave Form Controlled Alternatives

Arc voltage/Welding current
50 35 30 25 20 15 10 5 0
ROOT Fill

100

150

200

250

300

350

Pulse / Spray Power Mode STT Pulse RapidArc

Lincoln Lincoln Electric ElectricAlternatives Alternativesto tooffer offer

STT Process

STT

STT principle

Good Goodfusion fusionand and setting settingof ofthe the proper properarc arclength length

O veral O veralheat heat

input input(wetting) (wetting)

Movie
Reason Reasonfor forlower lower spatter spatterin inSTT STT

STT Process

Background current
Arc current level prior to shorting to the weld pool. Contributes to the overall heat input Keeps arc lit

Background current (T0 - T1): This is the current level of the arc prior to shorting to the weld pool. It is a steady-state current level, between 50 and 100 A

STT Process

Initial Shorting Response to the arc voltage detector sensing that the arc has shorted Current is reduced even further at actual ball/weld puddle contact Extremely low current promotes ball wetting instead of repelling Reason for lower spatter in STT

Ball time: When the electrode initially shorts (at the background current), the "arc voltage" detector provides a signal that the "arc" is shorted. The background current is futher reduced to 10 A for approxiametly 0.75 milliseconds. This time interval is referred to as the ball time.

STT Process

Pinch Current High current is applied immediately after the initial short Current increases, causing the molten droplet to separate from the electrode STT electronically calculates when droplet separation is to occur and reduces the current before this happens, eliminating the explosive spatter.

Pinch mode (T2 - T3): Following the ball time, a high current is applied to the shorted electrode in the form of an increasing, dual slope ramp. This accelerates the transfer of molten metal from the electrode to the weld pool by applying electronic pinch forces.

STT Process

Second Current Reduction Current is quickly reduced before electrode separates, eliminating spatter STT circuitry re-establishes the welding arc at a low current level

The dv/dt calculation: This calculation is included within the pinch mode. It is the calculation of the rate of change of the shorted electrode voltage vs. time. When this calculation indicates that a specific dv/dt value has been attained, indicating that fuse separation is about to occur, the current is reduced to 50 A in microseconds. (Note, this event occurs before the shorted electrode separates. T4indicates the separation has occurred, but at a low current.

STT Process

Peak Current High current is applied immediately after the arc is reestablished Arc is momentarily broadened, producing high heating of the plate, insuring good fusion and setting the proper arc length

Plasma boost (T5 - T6): This mode follows immediately the separation of the electrode from the weld pool. It is the period of high arc current where the electrode is quickly "melted back." (The geometry of the melted electrode at this point is very irregular.)

STT Process

Tailout Current is reduced from peak to background level Reduces agitation of the weld puddle This control is a coarse heat control

Plasma (T6 - T7): This is the period of the cycle where the arc current is reduced from plasma boost to the background current level.

movie

Movie

Peak & Background Current

STT settings
Peak current Providing the energy to set the arc length. Setting according wire diameter and composition. Pressure in both ways; wire and weld bead. Peak current = arc pressure & length

Low High Back ground current Providing the overall heat More or less wetting. Most used control on the STT. Back ground = Wetting Tail out In the same way as background To be use with high travel speed Automation not for pipe welding

Application; Stainless preparation

Preparation; Stainless
Tack weld with bar Tape Application: Pipe diameter 10 Position: Material: AISI 316L x 8 mm G3

60

3mm

Backing gas: 95%Ar 5%N2

Application Stainless pipe

Application: Stainless Root Pass

STT Root LNM 316LSI 1,0mm Gas: Ar + 2%CO2 Peak 270A Background 80A WFS 168/min Position 3GD

PULSE Fill LNM316LSI 1,0mm Gas: Ar + 2%Co2 22V, 175Amp Position 3GU (!)

Pulse CAP LNM316LSI 1,0mm Gas Ar + 2%CO2 22 V, 175Amps Position 3GU

Cor a Rosta

Welding stainless Example 7

Cor a Rosta wires are available in most used grades and increased productivity justifies the move to premium quality wires!!!

Example 7

Gates for shipbuilding

n-1 2 1 n

Example 7

10 mm

LNB

PA, 10 mm thick palte, gap 3-4mm, root 1,5, beveling V60

Bead# Method, wire
136, Cor aArosta 316L 136, Cor- a Rosta 316L

d, mm

I, A

U, V

Gas

Current, polarity DC+

Welding Speed, mm/sek 5,5-6

HI kJ/mm 0,5

Remark

1,2

155

24

M21

2 -n

1,2

182

26

M21

DC+

5,5-6

0,65

Overmaching corrosion resistance

Application: Pipe welding

Application; Steel Root Pass

Application: Pipe diameter 6 Position: 60 Material: X42 x 10mm G3(D) STT Root Supra MIG 1,0mm Gas: Ar + 20%CO2 Peak 280A Background 70A WFS 148/min Position 3GD

3mm

Fill Outershield 71E-H 1,2mm Gas: 80%Ar 20%Co2 26V, 215Amp Position 3GU

CAP Outershield 71E-H 1,2mm Gas Ar + 20%CO2 26 V, 215Amps Position 3GU

Setting STT Procedures

STT Welding Parameter Guideline & Joint Configuration Applicable for Un-, Low, & High Alloyed Materials (wire 1.0 mm)
Wall Thickness

Welding Position
1G / PA (Rotating) 5G Down / PG

< 3.5 mm

>3.5 mm
Wall Thickness <3.5 mm < 8 mm >8 mm
Peak Current Backgrond Current Wire Feed Speed Peak Current Backgrond Current Wire Feed Speed

230-240 260-270 260-270

50-65 55-65 65-85

290-330 330-360

230-240 250-260

45-55 50-65

290-330 320-360

360-420

Gas Selection

Shielding & Backing Gas Selection Table

Ar + 20% CO2 Ar + 20% CO2 + He Ar + 2% CO2 Ar + 28% He + 2%CO2 Ar + 30% He Ar + 28% He + 2%H2 Backing gas Ar N2 N2 + 5%H2 ++ + (+) * (+) (+) + + ++ ++ ++ + + ++ + + ++ Mild & Low Alloyed Steel ++ + Regular 3xx Stainless Steel ++ +* (Super) Duplex Stainless Steel + ++ Fully Austenitic Stainless Steel + ++ Nickel Alloys + ++

First option Second option Optional Not recommended Recommended when wall thickness > 6 mm

LSW06/AvdS-DR

Procedure Comparison

Procedure Comparison
25 mm 25 mm

3-4 mm Material Welding Position Pipe Diameter Consumable Classification Diameter Shielding gas Flow Backing gas Stick-out Peak Current Background Current Arc voltage Wire Feed Speed Welding Time 1.4462 (Duplex) 1G Rotating 25" LNM 4462 G 22 9 3 N L 1,2 mm 98% Ar + 2% CO2 13 l/min 100% Ar 12 mm 280 A 80 A 100 "/min 6 minutes Material Welding Position Pipe Diameter Consumable Classification Diameter Shielding gas Flow Backing gas Stick-out Current Arc voltage Wire Feed Speed Welding Time

3-4 mm 1.4462 (Duplex) 1G Rotating 25"

GMAW-STT

GTAW
LNT 4462 W 22 9 3 N L 2,4 mm 100% 8 l/min 100% Ar -90 A 11-13 V -22 minutes

Low Spatter, Defect Free Rootpass

Welding Fume

Solid wire (MIG/MAG, TIG & STT)

Fume emission (g/hour)

Welding current (A)

STT: 50% reduction in fume emission versus conventional GMAW

Industry Segments

Markets where STT can be applied

Oil & Gas Industry Cross Country Pipelines Power Generation Chemical Industry Pulp & Paper Industry Food & Dairy Industry

Base materials

Applications with the STT process Pipe Root-pass Welding Mild- & Fine Grained Steel Low Alloyed Steel Creep Resistant Steel (qualified and certified in Poland) Standard 3xx-series Stainless Steel Fully Austenitic Stainless Steel (Super)Duplex Stainless Steel Nickel Alloys

STT advantages

The The premium premium root root pass pass process process
Full electronically controlled arc. No risk of cold fusion. Different wires and gasses are applicable. Extremely low spatter Reduced smoke 4X faster compared to TIG welding Large ligament (5.5mm)

Thank you ksadurski@lincolnelectric.eu +48746461155